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Abstract:

Provided herein is a coated electroactive particle, comprising i) an
electroactive agglomerated particle that comprises a first and second
electroactive materials; and ii) a polymeric overcoating on the surface
of the electroactive agglomerated particle. Also provided herein is a
coated electroactive particle, comprising i) an agglomerated particle
that comprises subparticles of a first electroactive material and
subparticles of a second electroactive material; and ii) a polymeric
overcoating on the surface of the electroactive agglomerated particle.

Claims:

1-17. (canceled)

18. An electroactive agglomerated particle comprising a first
electroactive material and LiNi1-a-bAlaCobO2, where a
is from about 0.01 to about 0.5 and b is from about 0.01 to about 0.9,
with the proviso that the sum of a and b is less than 1.

19. The electroactive agglomerated particle of claim 18, comprising
subparticles of the first electroactive material and
LiNi1-a-bAlaCobO2 subparticles.

20-21. (canceled)

22. The electroactive agglomerated particle of claim 18, wherein the
electroactive agglomerated particle has an average particle size ranging
from about 0.1 μm to about 100 μm or from about 1 μm to about 50
μm.

23. (canceled)

24. The electroactive agglomerated particle of claim 18, wherein the
first electroactive material is LiMPO4 or (LiF)xFe1-x,
wherein M is a transition metal selected from the group consisting of Ti,
V, Cr, Mn, Fe, Co, and Ni; and wherein 0<x<1.

25. The electroactive agglomerated particle of claim 18, wherein the
first electroactive material is selected from the group consisting of
LiFePO4, LiMnPO4, LiVPO4, and mixtures thereof.

26. (canceled)

27. The electroactive agglomerated particle of claim 18, wherein a is
from about 0.01 to about 0.1 or b is from about 0.01 to about 0.2.

28. (canceled)

29. The electroactive agglomerated particle of claim 18, wherein the
LiNi1-a-bAlaCobO2 is
LiAl.sub.0.05Ni.sub.0.8Co.sub.0.15O2 or
LiAl.sub.0.03Ni.sub.0.8Co.sub.0.17O.sub.2.

30. The electroactive agglomerated particle of claim 18, comprising from
about 30 to about 95% by weight of the subparticles of the first
electroactive material and from about 70 to about 5% by weight of the
subparticles of LiNi1-a-bAlaCobO.sub.2.

31. The electroactive agglomerated particle of claim 18, wherein the
electroactive agglomerated particle further comprises at least one
diluent.

32. The electroactive agglomerated particle of claim 31, wherein the at
least one diluent is carbon.

33. The electroactive agglomerated particle of claim 31, wherein the at
least one diluent is a carbon nanoparticle.

34. (canceled)

35. The electroactive agglomerated particle of claim 31, wherein the
amount of the at least one diluent is ranging from about 1 to about 10%
by weight, from about 1 to about 5% by weight, or from about 1 to about
2% by weight.

36. The electroactive agglomerated particle of claim 18 further
comprising a binder.

37. The electroactive agglomerated particle of claim 36, wherein the
binder is selected from the group consisting of coal tar, sucrose, solid
ionic conductor, asphalt pitch, a polymeric binder, and mixtures thereof.

41. The electroactive agglomerated particle of claim 32, wherein the
electroactive agglomerated particle comprises from about 60% to about 90%
by weight of LiFePO4 or LiMnPO4, from about 30 to about 10% by
weight of LiNi1-a-bAlaCobO2, and from about 0.1% to
about 5% by weight of carbon, with the proviso that the total is no
greater than 100%.

42. The electroactive agglomerated particle of claim 32, wherein the
electroactive agglomerated particle comprises from about 65% to about 80%
by weight of LiFePO4 or LiMnPO4, from about 35 to about 20% by
weight of LiNi1-a-bAlaCobO2, and from about 1% to
about 2% by weight of carbon, with the proviso that the total is no
greater than 100%.

43-51. (canceled)

52. An electroactive agglomerated particle comprising from about 65% to
about 80% by weight of LiFePO4, from about 35 to about 20% by weight
of LiAl.sub.0.05Ni.sub.0.8Co.sub.0.15O2, and from about 1% to about
2% by weight of carbon.

53. An electroactive agglomerated particle comprising 70% by weight of
LiFePO4, about 30% of LiAl.sub.0.03Ni.sub.0.8Co.sub.0.17O2, and
about 1% by weight of a polyamideimide.

Description:

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application
Nos. 61/232,432, filed Aug. 9, 2009; and 61/307,851, filed Feb. 25, 2010;
the disclosure of each of which is incorporated herein by reference in
its entirety.

FIELD

[0002] Provided herein is a coated electroactive particle, comprising i)
an electroactive agglomerated particle that comprises a first and second
electroactive materials; and ii) a polymeric overcoating on the surface
of the electroactive agglomerated particle. Also provided herein is a
coated electroactive particle, comprising i) an agglomerated particle
that comprises subparticles of a first electroactive material and
subparticles of a second electroactive material; and ii) a polymeric
overcoating on the surface of the electroactive agglomerated particle.

BACKGROUND

[0003] There is great interest in developing rechargeable lithium
batteries with higher energy capacity and longer cycle life for
applications in, e.g., portable electronic devices, electric vehicles,
and implantable medical devices. Therefore, there is a need for a battery
with high capacity and/or sufficient cycle performance.

SUMMARY OF THE DISCLOSURE

[0004] Provided herein is a coated electroactive particle, comprising i)
an electroactive agglomerated particle that comprises a first and second
electroactive materials; and ii) a polymeric overcoating on the surface
of the electroactive agglomerated particle. In certain embodiments, the
electroactive agglomerated particle further comprises a diluent. In
certain embodiments, the electroactive agglomerated particle further
comprises a binder. In certain embodiments, the binder is a polymeric
binder. In certain embodiments, the binder is a polyamideimide. In
certain embodiments, the binder is a polyimide. In certain embodiments,
the polymeric overcoating is a polyamideimide. In certain embodiments,
the polymeric overcoating is a polyimide.

[0005] Also provided herein is a coated electroactive particle, comprising
i) an electroactive agglomerated particle that comprises subparticles of
a first electroactive material and subparticles of a second electroactive
material; and ii) a polymeric overcoating on the surface of the
electroactive agglomerated particle. In certain embodiments, the
electroactive agglomerated particle further comprises at least one
diluent subparticle. In certain embodiments, the electroactive
agglomerated particle further comprises a binder. In certain embodiments,
the binder is a polymeric binder. In certain embodiments, the binder is a
polyamideimide. In certain embodiments, the binder is a polyimide. In
certain embodiments, the polymeric overcoating is a polyamideimide. In
certain embodiments, the polymeric overcoating is a polyimide.

[0006] Further provided herein is a coated electroactive particle,
comprising an electroactive agglomerated particle that comprises a first
and second electroactive materials, and a polymeric binder; wherein the
surface of the electroactive agglomerated particle is coated with the
polymeric binder. In certain embodiments, the electroactive agglomerated
particles further comprise at least one diluent. In certain embodiments,
the polymeric binder is a polyamideimide. In certain embodiments, the
polymeric binder is a polyimide.

[0007] Additionally provided herein is a coated electroactive particle,
comprising an electroactive agglomerated particle that comprises a first
and second electroactive materials, and a polymeric binder; wherein the
surface of the electroactive agglomerated particle is coated with the
polymeric binder. In certain embodiments, the electroactive agglomerated
particles further comprise at least one diluent. In certain embodiments,
the polymeric binder is a polyamideimide. In certain embodiments, the
polymeric binder is a polyimide.

[0008] Provided herein is a coated electroactive particle, comprising an
electroactive agglomerated particle that comprises subparticles of a
first electroactive material, subparticles of a second electroactive
material, and a polymeric binder; wherein the surfaces of the
subparticles are coated with the polymeric binder. In certain
embodiments, the electroactive agglomerated particles further comprise at
least one diluent subparticle, wherein the surface of the diluent
subparticle is coated with the polymeric binder. In certain embodiments,
the polymeric binder is a polyamideimide. In certain embodiments, the
polymeric binder is a polyimide.

[0009] Provided herein is a coated electroactive particle, comprising an
electroactive agglomerated particle that comprises subparticles of a
first electroactive material, subparticles of a second electroactive
material, and a polymeric binder; wherein the surfaces of the
subparticles are substantially coated with the polymeric binder. In
certain embodiments, the electroactive agglomerated particles further
comprise at least one diluent subparticle, wherein the surface of the
diluent subparticle is substantially coated with the polymeric binder. In
certain embodiments, the polymeric binder is a polyamideimide. In certain
embodiments, the polymeric binder is a polyimide.

[0010] Provided herein is an electroactive agglomerated particle, which
comprises a first electroactive material and
LiNi1-a-bAlaCobO2, where a and b are each
independently from about 0.01 to about 0.9, with the proviso that the sum
of a and b is less than 1. In certain embodiments, the electroactive
agglomerated particle further comprises at least one diluent. In certain
embodiments, the electroactive agglomerated particles further comprise a
binder. In certain embodiments, the binder is a polymeric binder. In
certain embodiments, the polymeric binder is a polyamideimide. In certain
embodiments, the polymeric binder is a polyimide.

[0011] Provided herein is an electroactive agglomerated particle, which
comprises subparticles of a first electroactive material and
LiNi1-a-bAlaCobO2 subparticles, where a and b are
each independently from about 0.01 to about 0.9, with the proviso that
the sum of a and b is less than 1. In certain embodiments, the
electroactive agglomerated particle further comprises at least one
diluent subparticle. In certain embodiments, the electroactive
agglomerated particles further comprise a binder. In certain embodiments,
the binder is a polymeric binder. In certain embodiments, the polymeric
binder is a polyamideimide. In certain embodiments, the polymeric binder
is a polyimide.

[0012] Povided herein is an electroactive agglomerated particle, which
comprises a first electroactive material and
LiNi1-a-bAlaCobO2 subparticles, where a and b are
each independently from about 0.01 to about 0.9, with the proviso that
the sum of a and b is less than 1; wherein the
LiNi1-a-bAlaCobO2 subparticles are embedded in the
electroactive agglomerated particle. In certain embodiments, the
electroactive agglomerated particle further comprises at least one
diluent. In certain embodiments, the electroactive agglomerated particles
further comprise a binder. In certain embodiments, the binder is a
polymeric binder. In certain embodiments, the polymeric binder is a
polyamideimide. In certain embodiments, the polymeric binder is a
polyimide.

[0013] Provided herein is an electroactive agglomerated particle, which
comprises subparticles of a first electroactive material and
LiNi1-a-bAlaCobO2, where a and b are each
independently from about 0.01 to about 0.9, with the proviso that the sum
of a and b is less than 1; wherein the subparticles of the first
electroactive material are embedded in the electroactive agglomerated
particle. In certain embodiments, the electroactive agglomerated particle
further comprises at least one diluent. In certain embodiments, the
electroactive agglomerated particles further comprise a binder. In
certain embodiments, the binder is a polymeric binder. In certain
embodiments, the polymeric binder is a polyamideimide. In certain
embodiments, the polymeric binder is a polyimide.

[0014] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) covering the surfaces of
electroactive agglomerated particles with a layer of a polymer in a
solvent; and ii) curing the electroactive agglomerated particles at an
elevated temperature to form the coated electroactive particles.

[0015] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) covering the surfaces of
electroactive agglomerated particles with a layer of a mixture of
precursors of a polymer in a solvent; and ii) curing the electroactive
agglomerated particles at an elevated temperature form the coated
electroactive particles.

[0016] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) mixing electroactive
agglomerated particles with a polymer in a solvent to form a slurry; ii)
air-injecting the slurry to form particles; and iii) curing the particles
from step ii) at an elevated temperature to form the coated electroactive
particles.

[0017] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) mixing electroactive
agglomerated particles with a mixture of precursors of a polymer in a
solvent to form a slurry; ii) air-injecting the slurry to form particles;
and iii) curing the particles from step ii) at an elevated temperature to
form the coated electroactive particles.

[0018] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) mixing a first and second
electroactive materials with a polymer in a solvent to form a slurry; ii)
air-injecting the slurry to form agglomerated particles; and iii) curing
the agglomerated particles from step ii) at an elevated temperature to
form the coated electroactive particles.

[0019] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) mixing subparticles of a
first electroactive materials and subparticles of a second electroactive
material with a polymer in a solvent to form a slurry; ii) air-injecting
the slurry to form agglomerated particles; and iii) curing the
agglomerated particles from step ii) at an elevated temperature to form
the coated electroactive particles.

[0020] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) mixing a first and second
electroactive materials with a mixture of precursors of a polymer in a
solvent to form a slurry; ii) air-injecting the slurry to form coated
particles; and iii) curing the coated particles from step ii) at an
elevated temperature to form the coated electroactive particles.

[0021] Provided herein is a method for preparing the coated electroactive
particles, which comprises the steps of: i) mixing subparticles of a
first electroactive material and subparticles of a second electroactive
material with a mixture of precursors of a polymer in a solvent to form a
slurry; ii) air-injecting the slurry to form particles; and iii) curing
the particles from step ii) at an elevated temperature to form the coated
electroactive particles.

[0022] Provided herein is a method for preparing the electroactive
agglomerated particles, which comprises mixing a first and second
electroactive materials to form electroactive agglomerated particles. In
one embodiment, the method further comprises heating the electroactive
agglomerated particles at an elevated temperature.

[0023] Provided herein is a method for preparing the electroactive
agglomerated particles, which comprises mixing subparticles of a first
electroactive material and subparticles of a second electroactive
material to form electroactive agglomerated particles. In one embodiment,
the method further comprises curing the electroactive agglomerated
particles at an elevated temperature.

[0024] Provided herein is a method for preparing the electroactive
agglomerated particles, which comprises the steps of: i) mixing a first
and second electroactive materials with a polymer in a solvent to form a
slurry; and ii) air-injecting the slurry to form electroactive
agglomerated particles. In one embodiment, the method further comprises
curing the electroactive agglomerated particles at an elevated
temperature.

[0025] Provided herein is a method for preparing the electroactive
agglomerated particles, which comprises the steps of: i) mixing
subparticles of a first electroactive materials and subparticles of a
second electroactive material with a polymer in a solvent to form a
slurry; and ii) air-injecting the slurry to form electroactive
agglomerated particles. In one embodiment, the method further comprises
heating the electroactive agglomerated particles at an elevated
temperature.

[0026] Provided herein is a method for preparing the electroactive
agglomerated particles, which comprises the steps of: i) mixing a first
and second electroactive materials with a mixture of precursors of a
polymer in a solvent to form a slurry; and ii) air-injecting the slurry
to form electroactive agglomerated particles. In one embodiment, the
method further comprises heating the electroactive agglomerated particles
at an elevated temperature.

[0027] Provided herein is a method for preparing the electroactive
agglomerated particles, which comprises the steps of: i) mixing
subparticles of a first electroactive material and subparticles of a
second electroactive material with a mixture of precursors of a polymer
in a solvent to form a slurry; and ii) air-injecting the slurry to form
electroactive agglomerated particles. In one embodiment, the method
further comprises heating the electroactive agglomerated particles at an
elevated temperature.

BRIEF DESCRIPTION OF THE FIGURES

[0028] FIG. 1 is a schematic drawing of an agglomerated particle 11
comprising two types of subparticles, e.g., subparticles of a first
electroactive material 51 (clear circles) and subparticles of a second
electroactive material 52 (shaded circles).

[0029] FIG. 2 is a schematic drawing of an agglomerated particle 11
comprising a single type of subparticles, e.g., subparticles of a single
electroactive material 51.

[0030] FIG. 3 is a cross-sectional view of an electroactive agglomerated
particle 11 comprising a subparticle of a first electroactive material 51
(an open circle) embedded in a second electroactive material 52 (a shaded
circle).

[0031] FIG. 4 is a cross-sectional view of an electroactive agglomerated
particle 11 of a first electroactive material 51 (a clear circle)
embedded with subparticles (e.g., nanoparticles) of a second
electroactive material 52 (shaded circles).

[0032] FIG. 5 is a cross-sectional view of a coated electroactive particle
1, comprising i) an electroactive agglomerated particle 11 (a big inner
circle) that comprises subparticles of a first electroactive material 51
(open circles), subparticles of a second electroactive material 52
(shaded circles) or subparticles of a diluent material 53 (shaded
circles), and optionally a binder 61; and ii) a polymeric overcoating 62
(dotted area) on the surface of the electroactive agglomerated particle
11.

[0033]FIG. 6 is a cross-sectional view of a coated electroactive particle
1, comprising an electroactive agglomerated particle 11 (a big circle)
that comprises subparticles of a first electroactive material 51 (open
circles), subparticles of a second electroactive material 52 (shaded
circles) or subparticles of a diluent material 53 (shaded circles), and a
polymeric binder 63 (dotted area within the big circle).

[0034] FIGS. 7A, 7B, 7C, and 7D are SEM images of coated electroactive
particles that were prepared from LiFePO4 and doped LiNiO2
nanoparticles, and a polyamideimide.

[0035] FIGS. 8A, 8B, 8C, and 8D are SEM images of coated electroactive
particles that were prepared from LiFePO4 and doped LiNiO2
nanoparticles, and a polyamideimide.

[0036] FIGS. 9A and 9B are EDX spectra of two individual coated
electroactive particles, which were prepared from LiFePO4 and doped
LiNiO2 nanoparticles, and a polyamideimide.

[0037] FIGS. 10A, 10B, 10C, and 10D are SEM images of coated electroactive
particles that were prepared from LiFePO4 and doped LiNiO2
nanoparticles, and CMC.

DETAILED DESCRIPTION

[0038] To facilitate understanding of the disclosure set forth herein, a
number of terms are defined below.

[0039] Generally, the nomenclature used herein and the laboratory
procedures in electrochemistry, inorganic chemistry, polymer chemistry,
organic chemistry, and others described herein are those well known and
commonly employed in the art. Unless defined otherwise, all technical and
scientific terms used herein generally have the same meaning as commonly
understood by one of ordinary skill in the art to which this disclosure
belongs.

[0040] The term "metal" refers to both metals and metalloids, including
silicon and germanium. The phrase "a main group metal" is intended to
include Sn, Si, Al, Bi, Ge, and Pb.

[0041] The term "anode" or "negative electrode" refers to an electrode
where electrochemical oxidation occurs during discharging process. For
example, an anode undergoes delithiation during discharging.

[0042] The term "cathode" or "positive electrode" refers to an electrode
where electrochemical reduction occurs during discharging process. For
example, a cathode undergoes lithiation during discharging.

[0043] The term "charging" refers to a process of providing electrical
energy to an electrochemical cell.

[0044] The term "discharging" refers to a process of removing electrical
energy from an electrochemical cell. In certain embodiments, discharging
refers to a process of using the electrochemical cell to do useful work.

[0045] The term "electrochemically active," "electrically active," and
"electroactive" are used interchangeably and refer to a material that is
capable to incorporate lithium in its atomic lattice structure.

[0046] The term "lithiation" refers to a chemical process of inserting
lithium into an electroactive material in an electrochemical cell. In
certain embodiments, an electrode undergoes electrochemical reduction
during lithiation process.

[0047] The term "delithiation" refers to a chemical process of removing
lithium from an electroactive material in an electrochemical cell. In
certain embodiments, an electrode undergoes electrochemical oxidation
during delithiation process.

[0048] The term "about" or "approximately" means an acceptable error for a
particular value as determined by one of ordinary skill in the art, which
depends in part on how the value is measured or determined. In certain
embodiments, the term "about" or "approximately" means within 1, 2, 3, or
4 standard deviations. In certain embodiments, the term "about" or
"approximately" means within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%,
3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

Coated Electroactive Particle

[0049] In one embodiment, provided herein is a coated electroactive
particle, comprising i) an electroactive agglomerated particle that
comprises a first and second electroactive materials; and ii) a polymeric
overcoating on the surface of the electroactive agglomerated particle. In
certain embodiments, the surface of the electroactive agglomerate
particle is substantially covered by the polymeric overcoating.

[0050] In another embodiment, provided herein is a coated electroactive
particle, comprising i) an electroactive agglomerated particle comprising
subparticles of a first electroactive material and subparticles of a
second electroactive material; and ii) a polymeric overcoating on the
surface of the agglomerated particle. In certain embodiments, the surface
of the electroactive agglomerate particle is substantially covered by the
polymeric overcoating.

[0051] In certain embodiments, the electroactive agglomerated particle
further comprises at least one diluent. In certain embodiments, the
electroactive agglomerated particle further comprises at least one
diluent subparticle.

[0052] In certain embodiments, the electroactive agglomerated particle
further comprises a binder. In certain embodiments, the binder is
polymeric binder. In certain embodiments, the polymeric binder is a
polyamideimide. In certain embodiments, the polymeric binder is a
polyimide.

[0053] In certain embodiments, the polymeric overcoating is a
polyamideimide. In certain embodiments the polymeric overcoating is a
polyimide.

[0054] In certain embodiments, the polymeric binder and polymeric
overcoating are different. In certain embodiments, the polymeric binder
and polymeric overcoating are the same polymer. In certain embodiments,
the polymeric binder and polymeric overcoating are the same
polyamideimide. In certain embodiments, the polymeric binder and
polymeric overcoating are the same polyimide.

[0055] In yet another embodiment, provided herein is a coated
electroactive particle, which comprises an electroactive agglomerated
particle comprising a first and second electroactive materials, and a
polymeric binder; wherein the surface of the electroactive agglomerated
particle is coated with the polymeric binder. In certain embodiments, the
polymeric binder is a polyamideimide. In certain embodiments, the
polymeric binder is a polyimide.

[0056] In yet another embodiment, provided herein is a coated
electroactive particle, which comprises an electroactive agglomerated
particle comprising subparticles of a first electroactive material,
subparticles of a second electroactive material, and a polymeric binder;
wherein the surfaces of the electroactive subparticles are coated with
the polymeric binder. In certain embodiments, the polymeric binder is a
polyamideimide. In certain embodiments, the polymeric binder is a
polyimide.

[0057] In yet another embodiment, provided herein is a coated
electroactive particle, which comprises an electroactive agglomerated
particle comprising a first and second electroactive materials, and a
polymeric binder; wherein the surface of the electroactive agglomerated
particle is substantially coated with the polymeric binder. In certain
embodiments, the polymeric binder is a polyamideimide. In certain
embodiments, the polymeric binder is a polyimide.

[0058] In yet another embodiment, provided herein is a coated
electroactive particle, which comprises an electroactive agglomerated
particle comprising subparticles of a first electroactive material,
subparticles of a second electroactive material, and a polymeric binder;
wherein the surfaces of the electroactive subparticles are substantially
coated with the polymeric binder. In certain embodiments, the polymeric
binder is a polyamideimide. In certain embodiments, the polymeric binder
is a polyimide.

[0059] In one embodiment, the electroactive agglomerated particle further
comprises at least one diluent. In another embodiment, the electroactive
agglomerated particle further comprises at least one diluent subparticle,
wherein the surface of the diluent subparticle is substantially coated
with the polymeric binder.

[0061] The coated electroactive particle provided herein can have various
shapes, including, but not limited to, sphere, spheroid, platelet,
fibril, or fiber. In certain embodiments, the coated electroactive
particle is substantially spherical. In certain embodiments, the coated
electroactive particle is spherical. In certain embodiments, the coated
electroactive particle is spheroidal. In certain embodiments, the coated
electroactive particle is in the shape of fibril or fiber.

[0062] In certain embodiments, the coated electroactive particle has an
average particle size ranging from about 100 nm to about 100 μm, from
about 500 nm to about 50 μm, from about 1 to about 20 μm, from
about 2 to about 15 μm, from about 3 to about 10 μm, or from about
3 to about 5 μm. In certain embodiments, the coated electroactive
particle has an average particle size of about 1 μm, about 2 μm,
about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7
μm, about 8 μm, about 9 μm, or about 10 μm. In certain
embodiments, the coated electroactive particle has an average particle
size of about 3 μm. In certain embodiments, the coated electroactive
particle has an average particle size of about 4 μm. In certain
embodiments, the coated electroactive particles have an average particle
size of about 5 μm.

[0063] In certain embodiments, the coated electroactive particle in the
shape of sphere or platelet has an average particle size ranging from
about 100 nm to about 100 μm, from about 500 nm to about 50 μm,
from about 1 to about 20 μm, from about 2 to about 15 μm, from
about 3 to about 10 μm, or from about 3 to about 5 μm. In certain
embodiments, the coated electroactive particle in the shape of sphere or
platelet has an average particle size of about 1 μm, about 2 μm,
about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7
μm, about 8 μm, about 9 μm, or about 10 μm. In certain
embodiments, the coated electroactive particle in the shape of sphere or
platelet has an average particle size of about 3 μm. In certain
embodiments, the coated electroactive particle in the shape of sphere or
platelet has an average particle size of about 4 μm. In certain
embodiments, the coated electroactive particle in the shape of sphere or
platelet has an average particle size of about 5 μm.

[0064] In certain embodiments, the coated electroactive particle in the
shape of spheroid has an average particle size ranging from about 100 nm
to about 100 μm, from about 500 nm to about 50 μm, from about 1 to
about 20 μm, from about 2 to about 15 μm, from about 3 to about 10
μm, or from about 3 to about 5 μm. In certain embodiments, the
coated electroactive particle in the shape of spheroid has an average
particle size of about 1 μm, about 2 μm, about 3 μm, about 4
μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about
9 μm, or about 10 μm. In certain embodiments, the coated
electroactive particle in the shape of spheroid has an average particle
size of about 3 μm. In certain embodiments, the coated electroactive
particle in the shape of spheroid has an average particle size of about 4
μm. In certain embodiments, the coated electroactive particle in the
shape of spheroid has an average particle size of about 5 μm.

[0065] In certain embodiments, the coated electroactive particle in the
shape of fibril or fiber has an average diameter ranging from about 1 to
about 500 nm, from about 2 to about 250 nm, from about 5 to about 100 nm,
from about 10 to about 50 nm, or from about 20 to about 40 nm. In certain
embodiments, the coated electroactive particle in the shape of fibril or
fiber has an average diameter of about 5 nm, about 10 nm, about 15 nm,
about 20 nm, about 25 nm, about 30 nm, about 35 nm, about 40 nm, about 45
nm, about 50 nm, about 60 nm, about 70 nm, about 80 nm, about 90 nm, or
about 100 nm. In certain embodiments, the coated electroactive particle
in the shape of fibril or fiber has an average particle size of about 20
to about 40 nm. In certain embodiments, the coated electroactive particle
in the shape of fibril or fiber has an average particle size of about 25
nm.

[0066] In certain embodiments, the coated electroactive particle in the
shape of fibril or fiber has an average length ranging from about 50 nm
to about 1,000 μm, from about 50 nm to about 100 μm, or from about
50 nm to about 10 μm. In certain embodiments, the coated electroactive
particle in the shape of fibril or fiber has an average length of about
50 nm, about 100 nm, about 250 nm, about 500 nm, about 1 μm, about 2
μm, about 5 μm, about 10 μm, about 20 μm, or about 100 μm.

[0067] The particle sizes and particle size distributions of the particles
and subparticles provided herein can be determined using any methods
known to by one of ordinary skill in the art, including, but not limited
to, laser light scattering and microscopic imaging.

[0068] In certain embodiments, the coated electroactive particle has an
average surface area ranging from about 0.1 to about 100 m2/g, from
about 1 to about 50 m2/g, from about 2 to about 20 m2/g, from
about 5 to about 20 m2/g, from about 2 to about 15 m2/g, from
about 2 to about 10 m2/g, or from about 10 to about 15 m2/g.

[0069] In certain embodiments, the coated electroactive particle is
porous. In certain embodiments, the coated electroactive particle has
porosity as measured by density, ranging from about 0.1 to about 5
g/cm3, from about 0.2 to about 3 g/cm3, from about 0.5 to about
2 g/cm3, or from about 0.5 to about 1 g/cm3. In certain
embodiments, the coated electroactive particle has porosity of about 0.5,
about 1, about 1.5, about 2, about 2.5, about 3, about 3.5, about 4,
about, 4.5, or about 5 g/cm3.

[0070] In certain embodiments, the coated electroactive particles have
such particle size distribution that 10% of the coated electroactive
particles have a particle size of about 0.05 μm, about 0.1 μm, or
about 1 μm; and 90% of the coated electroactive particles have a
particle size of about 100 μm, about 50 μm, about 20 μm, about
10 μm, or about 5 μm. In certain embodiments the coated
electroactive particles have such particle size distribution that 10% of
the coated electroactive particles have a particle size of about 1 μm
and 90% of the coated electroactive particles have a particle size of
about 10 μm.

[0071] In certain embodiments, the coated electroactive particle has a
particle size ranging from about 100 nm to about 500 μm, from about
200 nm to about 200 μm, from about 500 nm to about 100 μm, from
about 1 to about 50 μm, from about 10 to about 50 μm, from about 10
to about 40 μm, from about 10 to about 30 μm, or from about 10 to
about 20 μm. In certain embodiments, the coated electroactive particle
has a particle size in the range from about 1 to about 50 μm.

[0072] In certain embodiments, the volume change of the coated
electroactive particle during a charging/discharging cycle is no more
than about 400%, no more than about 350%, no more than about 300%, no
more than about 250%, no more than about 200%, no more than about 150%,
no more than 100%, no more than about 50%, no more than about 25%, or no
more than about 10%.

[0073] Without being bound to any theory, one advantage of the coated
electroactive particle is that the electroactive particle can be used to
make electrodes using conventional processing techniques, such as reverse
roll coating or doctor blade coating. Without being bound to any theory,
another advantage is that one of the two electroactive materials in the
coated electroactive particle can enhance the electrical or ionic
conductivity of the other without reducing specific capacity. For
example, with the coated electroactive particle that comprises an
electroactive agglomerated particle comprising LiFePO4 and
LiAlNiCoO2 subparticles, the voltage behaviors of both the
LiFePO4 and LiAlNiCoO2 materials are retained, so that the
coated electroactive particle behaves as a superposition of the two.

Electroactive Agglomerated Particle

[0074] In one embodiment, provided herein is an electroactive agglomerated
particle comprising two or more electroactive materials. In another
embodiment, provided herein is an electroactive agglomerated particle
comprising at least two types of electroactive subparticles. In yet
antoher embodiment, the at least two types of subparticles each comprise
a different electroactive material. In still another embodiment, the
first type is subparticles of a first electroactive material, and the
second type is subparticles of a second electroactive material.

[0075] In one embodiment, provided herein is an electroactive agglomerated
particle comprising a first and second electroactive materials.

[0076] In another embodiment, provided herein is an electroactive
agglomerated particle comprising subparticles of a first electroactive
material and subparticles of a second electroactive material. In certain
embodiment, the electroactive agglomerated particle is as shown in FIG.
1.

[0077] In yet another embodiment, provided herein is an electroactive
agglomerated particle comprising a first electroactive material and
LiNi1-a-bAlaCobO2, where a and b are each as defined
herein.

[0078] In yet another embodiment, provided herein is an electroactive
agglomerated particle comprising subparticles of a first electroactive
material and LiNi1-a-bAlaCobO2 subparticles, where a
and b are each as defined herein.

[0079] In yet another embodiment, provided herein is an electroactive
agglomerated particle comprising a first electroactive material and
LiNi1-a-bAlaCobO2 subparticles, where a and b are
each as defined herein; wherein the LiNi1-a-bAlaCobO2
subparticles are embedded in the electroactive agglomerated particle
(FIG. 3 or 4).

[0080] In still another embodiment, provided herein is an electroactive
agglomerated particle comprising subparticles of a first electroactive
material and LiNi1-a-bAlaCobO2, where a and b are
each as defined herein; wherein the subparticles of the first
electroactive material are embedded in the electroactive agglomerated
particle (FIG. 3 or 4).

[0081] In one embodiment, the electroactive agglomerated particle provided
herein further comprises at least one diluent or diluent subparticle. In
certain embodiments, the amount of the at least one diluent or diluents
subparticle in the electroactive agglomerated particle is ranging from
about 0.01 to about 20% by weight, from about 0.05 to about 10% by
weight, from about 1 to about 10% by weight, from about 0.1 to about 5%
by weight, from about 1 to about 5% by weight, from about 0.2 to about 2%
by weight, from about 1 to about 2% by weight, from about 0.3 to about
1.5% by weight, or from about 0.5 to about 1% by weight of the
electroactive agglomerated particle. In certain embodiments, the amount
of the at least one diluent or diluents subparticle in the electroactive
agglomerated particle is ranging from about 1 to about 10% by weight,
from about 1 to about 5% by weight, from about 1 to about 2% by weight,
from about 0.3 to about 1.5% by weight, or from about 0.5 to about 1% by
weight of the electroactive agglomerated particle. In certain
embodiments, the amount of the at least one diluent or diluents
subparticle in the electroactive agglomerated particle is about 0.3% by
weight, about 0.5% by weight, about 0.7% by weight, about 0.9% by weight,
about 1% by weight, about 1.1% by weight, about 1.2% by weight, about
1.3% by weight, about 1.4% by weight, about 1.5% by weight, about 1.6% by
weight, about 1.7% by weight, about 1.8% by weight, about 1.9% by weight,
about 2% by weight, about 2.5% by weight, about 3% by weight, about 3.5%
by weight, about 4% by weight, about 4.5% by weight, or about 5% by
weight of the electroactive agglomerated particle.

[0083] In certain embodiments, the diluent or diluent subparticle is
carbon. In certain embodiments, the diluent or diluent subparticle is a
carbon subparticle. In certain embodiments, the diluent or diluent
subparticle is a carbon nanoparticle. In certain embodiments, the diluent
or diluent subparticle is a disordered carbon nanoparticle. In certain
embodiments, the diluent or diluent subparticle is a graphite
nanoparticle. In certain embodiments, the diluent or diluent subparticle
is a carbon nanotube. In certain embodiments, the diluent or diluent
subparticle is a carbon SWNT. In certain embodiments, the diluent or
diluent subparticle is a carbon MWNT. In certain embodiments, the diluent
or diluent subparticle is a carbon nanofiber. In certain embodiments, the
diluent or diluent subparticle is an Al nanoparticle or Ti nanoparticle.

[0084] In certain embodiments, the diluent or diluent subparticle used
herein has various shapes, including, but not limited to, sphere,
spheroid, fibril, fiber, or platelet. In certain embodiments, the diluent
subparticle used herein is substantially spherical. In certain
embodiments, the diluent subparticle used herein is spherical. In certain
embodiments, the diluent subparticle used herein is spheroid.

[0085] In certain embodiments, the diluent or diluent subparticle used
herein has an average particle size ranging from about 10 nm to about 100
μm, from about 10 nm to about 10 μm, from about 20 nm to about 5
μm, from about 20 nm to about 1 μm, from about 20 to about 500,
from about 50 to about 500 nm, from about 50 to about 400 nm, from about
50 to about 200 nm, or from about 100 to about 200 nm. In certain
embodiments, the diluent subparticle used herein has an average particle
size ranging about 50 nm, about 100 nm, about 150 nm, about 200 nm, about
300 nm, about 400 nm, about 500 nm, about 1 μm, about 2 μm, about 5
μm, or about 10 μm. In certain embodiments, the diluent subparticle
used herein has an average particle size ranging from about 10 to about
500 nm, from about 10 to about 200 nm, or from about 20 to about 100 nm.

[0087] In certain embodiments, the binder is asphalt pitch, pitch coke,
petroleum coke, sugars, coal tar, fluoranthene, pyrene, chrysene,
phenanthrene, anthracene, naphthalin, fluorine, biphenyl, or
acenephthene, wherein the binder is subsequently carbonized, in one
embodiment, in an inert gas atmosphere, so that the subparticles are
coated with and bound together by a carbonized layer. In one embodiment,
the amount of the carbonized binder in the electroactive agglomerated
particle is ranging from about 0.1 to about 20%, from about 0.5 to about
10%, or from about 1 to about 5% of the weight of the electroactive
agglomerated particle. In certain embodiments, the inert gas that is used
in the carbonization process is argon, nitrogen, or carbon dioxide. In
certain embodiments, the carbonization is performed at a temperature
ranging from about 250 to about 1,000° C., from about 300 to about
900° C., from about 400 to about 800° C., or from about 500
to about 700° C.

[0088] In certain embodiments, the binder is a solid ionic conductor. In
certain embodiments, the binder is a solid ionic conductor selected from
the group consisting of Li3PO4; a mixture of lithium nitride
and lithium phosphate; a mixture of lithium phosphorus oxynitride and
lithium phosphate;
Li1+x+y(Al,Ga)x(Ti,Ge)2-xSiyP3-yO12, where
0≦x≦1 and 0≦y≦1; and
LixSiyM.sub.zOvNw, where 0.3≦x≦0.46,
0.05≦y≦0.15, 0.016≦z≦0.05,
0.42≦v<0.05, 0≦x≦0.029, and M is selected from
the group consisting of Nb, Ta, and W.

[0096] In certain embodiments, the polymeric binder is formed from its
precursors via polymerization on the surface of the subparticles provided
herein. In certain embodiments, the precursors of a polymer are monomers
of the polymer. In certain embodiments, the polyamideimide as a polymeric
binder is formed from a polyanhydride and a polyamine via polymerization
on the surfaces of the subparticles. In certain embodiments, the
polyimide as a polymeric binder is formed from a polyanhydride and a
polyamine via polymerization on the surfaces of the subparticles. In
certain embodiments, the precursors of a polymer are crosslinkable
polymers. In certain embodiments, the polyamideimide as a polymeric
binder is formed from a polyamideimide via crosslinking on the surface of
the subparticles provided herein. In certain embodiments, the polyimide
as a polymeric binder is formed from a polyimide via crosslinking on the
surface of the subparticle provided herein.

[0097] In certain embodiments, the amount of the binder in the
electroactive agglomerated particle is ranging from about 0.1% to about
30%, from about 0.5% to about 20%, from about 1% to about 15%, from about
1% to about 10%, from about 1% to about 5%, or from about 2% to about 10%
of the weight of the electroactive agglomerated particle.

[0098] In certain embodiments, a conductive polymer is also added to the
polymeric binder to increase the conductivity of the electroactive
agglomerated particle. Suitable conductive polymers include, but are not
limited to, polythiophene, poly(3-hexylthiophene),
poly(2-acetylthiophene), polybenzothiopnene, poly(2,5-dimethylthiophene),
poly(2-ethylthiophene), poly(3-carboxylic ethyl thiophene),
polythiopheneacetonitrile, poly(3,4-ethylenedioxythiophene),
polyisothianaphthene, polypyrrole, polyaniline, polyparaphenylene, and
mixtures thereof. In certain embodiments, the conductive polymer is added
to the polymeric binder in an amount ranging from about 1 to about 40%,
from about 2 to about 20%, from about 3 to about 15%, or from about 5 to
about 10% of the total weight of the polymeric binder and conductive
polymer. In certain embodiments, the conductive polymer is added to the
polymeric binder first before contacting with the electroactive
agglomerated particle.

[0099] In one embodiment, the electroactive agglomerated particle provided
herein comprises LiFePO4 or LiMnPO4 (type 1), and
LiNicCo1-cO2 (type 2), wherein c is no less than 0 and no
greater than 1; or ranging from about 0.05 to about 0.95, from about 0.1
to about 0.90, from about 0.2 to about 0.5, or from about 0.2 to about
0.4. In one embodiment, c is ranging from about 0.2 to about 0.5 or from
about 0.2 to about 0.4, or about 0.3.

[0100] In another embodiment, the electroactive agglomerated particle
provided herein comprises subparticles of LiFePO4 or LiMnPO4
(type 1), and subparticles of LiNicCo1-cO2 (type 2),
wherein c is no less than 0 and no greater than 1; or ranging from about
0.05 to about 0.95, from about 0.1 to about 0.90, from about 0.2 to about
0.5, or from about 0.2 to about 0.4. In one embodiment, c is ranging from
about 0.2 to about 0.5 or from about 0.2 to about 0.4, or about 0.3.

[0103] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises LiFePO4 or LiMnPO4, and
LiNi1-a-bAlaCobO2 (type 2), where a and b are each as
defined herein.

[0104] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises subparticles of LiFePO4 or LiMnPO4
(type 1), and subparticles of LiNi1-a-bAlaCobO2 (type
2), where a and b are each as defined herein.

[0105] In one embodiment, the electroactive agglomerated particle
comprises from about 1 to about 99%, from about 30 to about 95%, from
about 50 to about 90%, from about 60% to about 90%, from about 60% to
about 80%, from about 65% to about 80%, from about 70% to about 80%, or
from about 80% to 90% by weight of the first electroactive material; and
from about 99 to about 1%, from about 70 to about 5%, from about 50 to
about 10%, from about 40 to about 10%, from about 40 to about 20%, from
about 35 to about 20%, from about 30 to about 20%, or from about 20 to
about 10% by weight of the second electroactive material, with the
proviso that the total is no greater than 100%.

[0106] In another embodiment, the electroactive agglomerated particle
comprises from about 50 to about 90% by weight of the first electroactive
material and from about 50 to about 10% by weight of the second
electroactive material with the proviso that the total is no greater than
100%.

[0107] In yet another embodiment, the electroactive agglomerated particle
comprises from about 60 to about 90% by weight of the first electroactive
material and from about 40 to about 10% by weight of the second
electroactive material with the proviso that the total is no greater than
100%.

[0108] In still another embodiment, the electroactive agglomerated
particle comprises from about 60 to about 80% by weight of the first
electroactive material and from about 40 to about 20% by weight of the
second electroactive material with the proviso that the total is no
greater than 100%.

[0109] In one embodiment, the electroactive agglomerated particle
comprises from about 1 to about 99%, from about 30 to about 95%, from
about 50 to about 90%, from about 60% to about 90%, from about 60% to
about 80%, from about 65% to about 80%, from about 70% to about 80%, or
from about 80% to 90% by weight of the subparticles (type 1) of the first
electroactive material; and from about 99 to about 1%, from about 70 to
about 5%, from about 50 to about 10%, from about 40 to about 10%, from
about 40 to about 20%, from about 35 to about 20%, from about 30 to about
20%, or from about 20 to about 10% by weight of the subparticles (type 2)
of the second electroactive material, with the proviso that the total is
no greater than 100%.

[0110] In another embodiment, the electroactive agglomerated particle
comprises from about 50 to about 90% by weight of the subparticles of the
first electroactive material and from about 50 to about 10% by weight of
the subparticles of the second electroactive material with the proviso
that the total is no greater than 100%.

[0111] In yet another embodiment, the electroactive agglomerated particle
comprises from about 60 to about 90% by weight of the subparticles of the
first electroactive material and from about 40 to about 10% by weight of
the subparticles of the second electroactive material with the proviso
that the total is no greater than 100%.

[0112] In still another embodiment, the electroactive agglomerated
particle comprises from about 60 to about 80% by weight of the
subparticles of the first electroactive material and from about 40 to
about 20% by weight of the subparticles of the second electroactive
material with the proviso that the total is no greater than 100%.

[0113] In one embodiment, the electroactive agglomerated particle provided
herein comprises LiFePO4 or LiMnPO4,
LiNicCo1-cO2, and a binder, wherein c is as defined
herein. In certain embodiments, the binder is coal tar. In certain
embodiments, the binder is a polymeric binder. In certain embodiments,
the binder is a crosslinkable polymer. In certain embodiments, the binder
is a polyamideimide. In certain embodiments, the binder is a polyimide.
In certain embodiments, the binder is carboxymethyl cellulose (CMC).

[0114] In another embodiment, the electroactive agglomerated particle
provided herein comprises subparticles of LiFePO4 or LiMnPO4,
subparticles of LiNicCo1-cO2, and a binder, wherein c is
as defined herein. In certain embodiments, the binder is coal tar. In
certain embodiments, the binder is a polymeric binder. In certain
embodiments, the binder is a crosslinkable polymer. In certain
embodiments, the binder is a polyamideimide. In certain embodiments, the
binder is a polyimide. In certain embodiments, the binder is
carboxymethyl cellulose (CMC).

[0116] In certain embodiments, the electroactive agglomerated particle
provided herein comprises subparticles of LiFePO4 or LiMnPO4,
subparticles of LiNicCo1-cO2, and coat tar, wherein c is
as defined herein. In certain embodiments, the electroactive agglomerated
particle provided herein comprises subparticles of LiFePO4 or
LiMnPO4, subparticles of LiNicCo1-cO2, and a
polyamideimide or polyimide, wherein c is as defined herein.

[0117] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises LiFePO4 or LiMnPO4, V2O5,
and a binder. In certain embodiments, the binder is coal tar. In certain
embodiments, the binder is a polymeric binder. In certain embodiments,
the binder is a crosslinkable polymer. In certain embodiments, the binder
is a polyamideimide. In certain embodiments, the binder is a polyimide.
In certain embodiments, the binder is carboxymethyl cellulose (CMC).

[0118] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises subparticles of LiFePO4 or LiMnPO4,
subparticles of V2O5, and a binder. In certain embodiments, the
binder is coal tar. In certain embodiments, the binder is a polymeric
binder. In certain embodiments, the binder is a crosslinkable polymer. In
certain embodiments, the binder is a polyamideimide. In certain
embodiments, the binder is a polyimide. In certain embodiments, the
binder is carboxymethyl cellulose (CMC).

[0120] In certain embodiments, the electroactive agglomerated particle
provided herein comprises subparticles of LiFePO4 or LiMnPO4,
subparticles of V2O5, and coat tar. In certain embodiments, the
electroactive agglomerated particle provided herein comprises
subparticles of LiFePO4 or LiMnPO4, subparticles of
V2O5, and a polyamideimide or polyimide.

[0121] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises LiFePO4 or LiMnPO4,
LiNi1-a-bAlaCobO2, and a binder, wherein a and b are
each as defined herein. In certain embodiments, the binder is coal tar.
In certain embodiments, the binder is a polymeric binder. In certain
embodiments, the binder is a crosslinkable polymer. In certain
embodiments, the binder is a polyamideimide. In certain embodiments, the
binder is a polyimide. In certain embodiments, the binder is
carboxymethyl cellulose (CMC).

[0122] In still another embodiment, the electroactive agglomerated
particle provided herein comprises subparticles of LiFePO4 or
LiMnPO4, subparticles of LiNi1-a-bAlaCobO2, and
a binder, wherein a and b are each as defined herein. In certain
embodiments, the binder is coal tar. In certain embodiments, the binder
is a polymeric binder. In certain embodiments, the binder is a
crosslinkable polymer. In certain embodiments, the binder is a
polyamideimide. In certain embodiments, the binder is a polyimide. In
certain embodiments, the binder is carboxymethyl cellulose (CMC).

[0123] In certain embodiments, the electroactive agglomerated particle
provided herein comprises LiFePO4 or LiMnPO4,
LiNi1-a-bAlaCobO2, and coat tar, wherein a and b are
each as defined herein. In certain embodiments, the electroactive
agglomerated particle provided herein comprises LiFePO4, and
LiNi1-a-bAlaCobO2 or LiMnPO4, and a
polyamideimide or polyimide, wherein a and b are each as defined herein.

[0124] In certain embodiments, the electroactive agglomerated particle
provided herein comprises subparticles of LiFePO4 or LiMnPO4,
subparticles of LiNi1-a-bAlaCobO2, and coat tar,
wherein a and b are each as defined herein. In certain embodiments, the
electroactive agglomerated particle provided herein comprises
subparticles of LiFePO4, subparticles of
LiNi1-a-bAlaCobO2 or LiMnPO4, and a
polyamideimide or polyimide, wherein a and b are each as defined herein.

[0125] In one embodiment, the electroactive agglomerated particle
comprises from about 30 to about 95% by weight of the first electroactive
material, from about 70 to about 5% by weight of the second electroactive
material, and from about 0.1 to about 5% by weight of the binder(s). In
another embodiment, the electroactive agglomerated particle comprises
from about 50 to about 90% by weight of the first electroactive material
and from about 50 to about 10% by weight of the second electroactive
material, and from about 0.1 to about 5% by weight of the binder(s). In
yet another embodiment, the electroactive agglomerated particle comprises
from about 60 to about 90% by weight of the first electroactive material
and from about 40 to about 10% by weight of the second electroactive
material, and from about 0.1 to about 5% by weight of the binder(s). In
yet another embodiment, the electroactive agglomerated particle comprises
from about 70 to about 90% by weight of the first electroactive material
and from about 30 to about 10% by weight of the second electroactive
material, and from about 0.1 to about 5% by weight of the binder(s).
Nevertheless, the total amount of all the ingredients in the agglomerates
should equal to 100%.

[0126] In one embodiment, the electroactive agglomerated particle
comprises from about 30 to about 95% by weight of the subparticles (type
1) of the first electroactive material, from about 70 to about 5% by
weight of the subparticles (type 2) of the second electroactive material,
and from about 0.1 to about 5% by weight of the binder(s). In another
embodiment, the electroactive agglomerated particle comprises from about
50 to about 90% by weight of the subparticles (type 1) of the first
electroactive material and from about 50 to about 10% by weight of the
subparticles (type 2) of the second electroactive material, and from
about 0.1 to about 5% by weight of the binder(s). In yet another
embodiment, the electroactive agglomerated particle comprises from about
60 to about 90% by weight of the subparticles of the first electroactive
material and from about 40 to about 10% by weight of the subparticles of
the second electroactive material, and from about 0.1 to about 5% by
weight of the binder(s). In yet another embodiment, the electroactive
agglomerated particle comprises from about 70 to about 90% by weight of
the subparticles of the first electroactive material and from about 30 to
about 10% by weight of the subparticles of the second electroactive
material, and from about 0.1 to about 5% by weight of the binder(s).
Nevertheless, the total amount of all the ingredients in the agglomerates
should equal to 100%.

[0127] In certain embodiments, the electroactive agglomerated particle
provided herein is a micrometer-sized particle. Without being bound to
any theory, such a micrometer-sized particle can increase the particle
flowability, and manufacturability of end products, e.g., electrodes for
a battery. In certain embodiments, the electroactive agglomerated
particle has an average particle size ranging from about 0.1 to about 100
μm, from about 0.5 to about 50 μm, from about 0.5 to about 20
μm, from about 1 to about 20 μm, from about 1 to about 10 μm,
from about 2 to about 20 μm, from about 2 to about 10 μm, from
about 3 to about 10 μm, from about 5 to about 12 μm, from about 6
to about 10 μm, from about 1 to about 5 μm, from about 2 to about 5
μm, or from about 3 to about 5 μm. In certain embodiments, the
electroactive agglomerated particle has an average particle size of about
1 μm, about 2 μm, about 3 μm, about 4 μm, about 5 μm,
about 6 μm, about 7 μm, about 8 μm, about 9, or about 10 μm.
In certain embodiments, the electroactive agglomerated particle has an
average particle size of about 3 μm. In certain embodiments, the
electroactive agglomerated particle has an average particle size of about
4 μm. In certain embodiments, the electroactive agglomerated particle
has an average particle size of about 5 μm.

[0128] In certain embodiments, the electroactive agglomerated particle has
an average surface area ranging from about 0.1 to about 100 m2/g,
from about 1 to about 50 m2/g, from about 2 to about 20 m2/g,
from about 5 to about 20 m2/g, from about 2 to about 15 m2/g,
from about 2 to about 10 m2/g, or from about 10 to about 15
m2/g.

[0129] In certain embodiments, the electroactive agglomerated particle is
porous. In certain embodiments, the electroactive agglomerated particle
has porosity as measured by density, ranging from about 0.1 to about 10
g/cm3, from about 0.2 to about 5 g/cm3, from about 0.5 to about
4 g/cm3, or from about 1 to about 3 g/cm3. In certain
embodiments, the electroactive agglomerated particle has porosity of
about 0.5, about 1, about 1.5, about 2, about 2.5, about 3, about 3.5,
about 4, about, 4.5, or about 5 g/cm3.

[0130] In certain embodiments, the electroactive agglomerated particles
have such particle size distribution that 10% of the electroactive
agglomerated particles have a particle size of about 0.05 μm, about
0.1 μm, or about 1 μm; and 90% of the electroactive agglomerated
particles have a particle size of about 100 μm, about 50 μm, about
20 μm, about 10 μm, or about 5 μm. In certain embodiments, the
electroactive agglomerated particles have such particle size distribution
that 10% of the electroactive agglomerated particles have a particle size
of 1 μm and 90% of the electroactive agglomerated particles have a
particle size of 10 μm.

[0131] In certain embodiments, the electroactive agglomerated particle has
a particle size ranging from about 100 nm to about 500 μm, from about
200 nm to about 200 μm, from about 500 nm to about 100 μm, from
about 1 to about 50 μm, from about 10 to about 50 μm, from about 10
to about 40 μm, from about 10 to about 30 μm, or from about 10 to
about 20 μm. In certain embodiments, the electroactive agglomerated
particle has a particle size in the range from about 1 to about 50 μm.

[0132] In certain embodiments, the electroactive agglomerated particle is
coated to provide additional desired chemical and/or physical properties,
such as chemical inertness (by coating with metal oxides, such as
TiO2, MoO3, WO3, Al2O3, or ZnO) or electrical
conductivity (by coating with, e.g., ionic conductors or carbon). In
certain embodiments, the electroactive agglomerated particle is coated
with a metal oxide by contacting the electroactive agglomerated particle
with the metal oxide, e.g., in a grinder. In certain embodiments, the
electroactive agglomerated particle is coated with a metal oxide by
contacting the electroactive agglomerated particle with a solution of
polytitanic acid, polytungstic acid, polymolybdic acid, polytitanic acid
peroxide, polytungstic acid peroxide, polymolybdic acid peroxide, or a
mixture thereof, to form the corresponding metal oxide upon dehydration.

[0133] In certain embodiments, the electroactive agglomerated particle is
coated with carbon by thermal vapor deposition (CVD), as described in
U.S. Pat. App. Pub. No. 2003/025711, the disclosure of which is
incorporated herein by reference in its entirety.

[0134] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of the
subparticles of the first electroactive material and from about 70 to
about 5% by weight of the subparticles of the second electroactive
material, with the proviso that the total is no greater than 100%.

[0135] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of the
first electroactive material and from about 70 to about 5% by weight of
the second electroactive material, with the proviso that the total is no
greater than 100%.

[0136] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of the
first electroactive material, from about 70 to about 5% by weight of the
second electroactive material, and from about 0.1 to about 5% by weight
of the binder; with the proviso that the total is no greater than 100%.

[0137] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of the
subparticles of the first electroactive material, from about 70 to about
5% by weight of the subparticles of the second electroactive material,
and from about 0.1 to about 5% by weight of the binder; with the proviso
that the total is no greater than 100%.

[0138] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of
LiFePO4 or LiMnPO4, and from about 70 to about 5% by weight of
LiNi1-a-bAlaCobO2, with the proviso that the total is
no greater than 100%; where a and b are each as defined herein.

[0139] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of
LiFePO4 or LiMnPO4 subparticles and from about 70 to about 5%
by weight of LiNi1-a-bAlaCobO2 subparticles, with the
proviso that the total is no greater than 100%; where a and b are each as
defined herein.

[0140] In certain embodiments, the electroactive agglomerated particle
provided herein comprises LiFePO4 or LiMnPO4,
LiNi1-a-bAlaCobO2, and at least one diluent, where a
and b are each as defined herein; wherein the diluent is selected from
the group consisting of carbon nanoparticles, in one embodiment, graphite
nanoparticle, disordered carbon nanoparticle, carbon nanotubes (SWNTs or
MWNTs), and carbon nanofibers; Al subparticles, Ti subparticles, and
mixtures thereof. In one embodiment, the diluent is a carbon
nanoparticle.

[0141] In certain embodiments, the electroactive agglomerated particle
provided herein comprises LiFePO4 or LiMnPO4 subparticles,
LiNi1-a-bAlaCobO2 subparticles, and at least one
diluent subparticle, where a and b are each as defined herein; wherein
the diluent subparticle is selected from the group consisting of carbon
nanoparticles, in one embodiment, graphite nanoparticle, disordered
carbon nanoparticle, carbon nanotubes (SWNTs or MWNTs), and carbon
nanofibers; Al subparticles, Ti subparticles, and mixtures thereof. In
one embodiment, the diluent subparticle is a carbon nanoparticle.

[0142] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of
LiFePO4 or LiMnPO4, from about 70 to about 5% by weight of
LiNi1-a-bAlaCobO2, and from about 0.1 to about 5% by
weight of carbon; with the proviso that the total is no greater than
100%; where a and b are each as defined herein.

[0143] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of
LiFePO4 or LiMnPO4 subparticles, from about 70 to about 5% by
weight of LiNi1-a-bAlaCobO2 subparticles, and from
about 0.1 to about 5% by weight of carbon subparticles; with the proviso
that the total is no greater than 100%; where a and b are each as defined
herein.

[0144] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 60 to about 90% by weight of
LiFePO4 or LiMnPO4, from about 40 to about 10% by weight of
LiNi1-a-bAlaCobO2, and from about 0.1 to about 5% by
weight of carbon; with the proviso that the total is no greater than
100%; where a and b are each as defined herein.

[0145] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 60 to about 90% by weight of
LiFePO4 or LiMnPO4 subparticles, from about 40 to about 10% by
weight of LiNi1-a-bAlaCobO2 subparticles, and from
about 0.1 to about 5% by weight of carbon subparticles; with the proviso
that the total is no greater than 100%; where a and b are each as defined
herein.

[0146] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 65 to about 80% by weight of
LiFePO4 or LiMnPO4, from about 35 to about 20% by weight of
LiNi1-a-bAlaCobO2, and from about 1 to about 2% by
weight of carbon; with the proviso that the total is no greater than
100%; where a and b are each as defined herein.

[0147] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 65 to about 80% by weight of
LiFePO4 or LiMnPO4 subparticles, from about 35 to about 20% by
weight of LiNi1-a-bAlaCobO2 subparticles, and from
about 1 to about 2% by weight of carbon subparticles; with the proviso
that the total is no greater than 100%; where a and b are each as defined
herein.

[0148] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of the
first electroactive material, from about 70 to about 5% by weight of the
second electroactive material, and from about 0.1 to about 5% by weight
of the binder; with the proviso that the total is no greater than 100%.

[0149] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of the
subparticles of the first electroactive material, from about 70 to about
5% by weight of the subparticles of the second electroactive material,
and from about 0.1 to about 5% by weight of the binder; with the proviso
that the total is no greater than 100%.

[0150] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of
LiFePO4, from about 70 to about 5% by weight of
LiNi1-a-bAlaCobO2, and from about 0.1 to about 5% by
weight of the binder; with the proviso that the total is no greater than
100%; where a and b are each as defined herein.

[0151] In certain embodiments, the electroactive agglomerated particle
provided herein comprises from about 30 to about 95% by weight of
LiFePO4 subparticles, from about 70 to about 5% by weight of
LiNi1-a-bAlaCobO2 subparticles, and from about 0.1 to
about 5% by weight of the binder; with the proviso that the total is no
greater than 100%; where a and b are each as defined herein.

[0152] In certain embodiments, the electroactive agglomerated particle
provided herein comprises about 70% by weight of LiFePO4, about 30%
by weight of LiNi1-a-bAlaCobO2, and about 1% by
weight of a binder; with the proviso that the total is no greater than
100%; where a and b are each as defined herein.

[0153] In certain embodiments, the electroactive agglomerated particle
provided herein comprises about 70% by weight of LiFePO4
subparticles, about 30% by weight of
LiNi1-a-bAlaCObO2 subparticles, and about 1% by
weight of a binder; with the proviso that the total is no greater than
100%; where a and b are each as defined herein.

[0154] In certain embodiments, a is 0.05 and b is 0.15. In certain
embodiments, a is 0.03 and b is 0.17. In certain embodiments, the second
electroactive material is LiAl0.05Ni0.8Co0.15O2.

[0155] In certain embodiments, the binder is a polyimide. In certain
embodiments, the binder is a polyamideimide. In certain embodiments, the
binder is CMC.

[0156] In one embodiment, the electroactive agglomerated particle provided
herein comprises about 78% by weight of LiFePO4, about 20% by weight
of LiAl0.05Ni0.8Co0.15O2, and about 1.5% by weight of
carbon.

[0157] In another embodiment, the electroactive agglomerated particle
provided herein comprises about 68% by weight of LiFePO4, about 30%
by weight of LiAl0.05Ni0.8Co0.15O2, and about 1.2% by
weight of carbon.

[0158] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises about 78% by weight of subparticles of
LiFePO4, about 20% by weight of subparticles of
LiAl0.05Ni0.8Co0.15O2, and about 1.5% by weight of
carbon.

[0159] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises about 68% by weight of subparticles of
LiFePO4, about 30% by weight of subparticles of
LiAl0.05Ni0.8Co0.15O2, and about 1.2% by weight of
carbon.

[0160] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises about 69% by weight of LiFePO4, about 30%
by weight of LiAl0.05Ni0.8Co0.15O2, and about 1% by
weight of polyamideimide.

[0161] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises about 69% by weight of subparticles of
LiFePO4, about 30% by weight of subparticles of
LiAl0.05Ni0.8Co0.15O2, and about 1% by weight of
polyamideimide.

[0162] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises about 69% by weight of LiFePO4, about 30%
by weight of LiAl0.05Ni0.8Co0.15O2, and about 1% by
weight of CMC.

[0163] In yet another embodiment, the electroactive agglomerated particle
provided herein comprises about 69% by weight of subparticles of
LiFePO4, about 30% by weight of subparticles of
LiAl0.05Ni0.8Co0.15O2, and about 1% by weight of CMC.

[0164] Without being bound to any theory, one advantage of the
electroactive agglomerated particle is that the electroactive particle
can be used to make electrodes using conventional processing techniques,
such as reverse roll coating or doctor blade coating. Without being bound
to any theory, another advantage is that one of the two electroactive
materials in the electroactive agglomerated particle can enhance the
electrical or ionic conductivity of the other without reducing specific
capacity. For example, with the electroactive agglomerated particle
comprising LiFePO4 and LiAlNiCoO2 subparticles, the voltage
behaviors of both the LiFePO4 and LiAlNiCoO2 materials are
retained, so that the electroactive agglomerated particle behaves as a
superposition of the two.

Electroactive Subparticles

[0165] In one embodiment, the first electroactive material is a lithium
compound. In one embodiment, the first electroactive material is a
lithium phosphate compound. In another embodiment, the first
electroactive material is LiMPO4, wherein M is a transition metal.
In yet another embodiment, M is a transition metal selected from the
group consisting of Ti, V, Cr, Mn, Fe, Co, and Ni. In yet another
embodiment, the first electroactive material is LiFePO4. In yet
another embodiment, the first electroactive material is LiMnPO4. In
yet another embodiment, the first electroactive material is LiVPO4.
In yet another embodiment, the first electroactive material is
AMa1-dMbdPO4, wherein A is Li, Na, or a mixture
thereof; Ma is Fe, Co, Mn, or a mixture thereof; Mb is Mg, Ca,
Zn, Ni, Co, Cu, Al, B, Cr, Nb, or a mixture thereof; and d is ranging
from about 0.01 to about 0.99, from about 0.01 to about 0.5, from about
0.01 to about 0.30, or from about 0.01 to about 0.15. In yet another
embodiment, the first electroactive material is
LiMa1-dMbdPO4, wherein Ma, Mb, and d
are each as defined herein. In yet another embodiment, the first
electroactive material is NaMa1-dMbdPO4, wherein
Ma, Mb, and d are each as defined herein. In still another
embodiment, the first electroactive material is (LiF)xFe1-x,
where 0<x<1, in one embodiment, x is 0.5.

[0166] In another embodiment, the second electroactive material is a metal
oxide. In one embodiment, the second electroactive material is selected
from the group consisting of LiCoO2, LiNiCoO2,
LiNicCo1-cO2, wherein c is from about 0.05 to about 0.95,
from about 0.1 to about 0.90, from about 0.2 to about 0.5, or from about
0.2 to about 0.4, Li(NiMnCo)1/3O2, Li(NiMn)1/2O2,
LiV2O5, and mixtures thereof. In yet another embodiment, the
second electroactive material is LiCoO2. In yet another embodiment,
the second electroactive material is LiNiCoO2. In still another
embodiment, the second electroactive material is LiMn2O4.

[0167] In yet another embodiment, the second electroactive material is
LiNicCo1-cO2, wherein c is ranging from about 0.05 to
about 0.95, from about 0.1 to about 0.90, from about 0.2 to about 0.5, or
from about 0.2 to about 0.4. In yet another embodiment, the second
electroactive material is LiNicCo1-cO2, wherein c is from
about 0.2 to about 0.5, from about 0.2 to about 0.4, or about 0.3. In yet
another embodiment, the second electroactive material is
Li(NiMnCo)1/3O2. In yet another embodiment, the second
electroactive material is Li(NiMn)1/2O2. In yet another
embodiment, the second electroactive material is LiV2O5.

[0168] In yet another embodiment, the second electroactive material is
LiNieMnfCo1-e-fO2, wherein e and f are each
independently ranging from 0 to about 0.95, from about 0.01 to about 0.9,
from about 0.05 to about 0.80, from about 0.1 to about 0.5, or from about
0.2 to about 0.4, and the sum of e and f is less than 1. In yet another
embodiment, the second electroactive material is
LiNieMnfCo1-e-fO2, wherein e and f are 0.33.

[0169] In still another embodiment, the second electroactive material is
LiNi1-a-bAlaCobO2, wherein a is from about 0.01 to
about 0.9, from about 0.01 to about 0.7, from about 0.01 to about 0.5,
from about 0.01 to about 0.4, from about 0.01 to about 0.3, from about
0.01 to about 0.2, or from about 0.01 to about 0.1; and b is from about
0.01 to about 0.9, from about 0.01 to about 0.7, from about 0.01 to about
0.5, from about 0.01 to about 0.4, from about 0.01 to about 0.3, from
about 0.01 to about 0.2, or from about 0.01 to about 0.1; with the
proviso that the sum of a and b is less than 1. In certain embodiments, a
is from about 0.01 to about 0.5. In certain embodiments, a is from about
0.01 to about 0.1. In certain embodiments, b is from about 0.01 to about
0.9. In certain embodiments, b is from about 0.01 to about 0.2. In
certain embodiments, a is from about 0.01 to about 0.1 and b is from
about 0.01 to about 0.2. In certain embodiments, the second electroactive
material is LiAlNiCoO2. In certain embodiments, the second
electroactive material is LiAl0.05Ni0.8Co0.15O2. In
certain embodiments, the second electroactive material is
LiAl0.03Ni0.8Co0.17O2.

[0170] Each type of the electroactive subparticles used herein can have
various shapes, including, but not limited to, sphere, spheroid, fibril,
fiber, or platelet. In certain embodiments, the electroactive
subparticles used herein are substantially spherical. In certain
embodiments, the electroactive subparticles used herein are spherical. In
certain embodiments, the electroactive subparticles used herein are
spheroidal.

[0171] In certain embodiments, each type of the electroactive subparticles
in the electroactive agglomerated particles independently has an average
particle size ranging from about 1 to about 500 nm, from about 1 to about
200 nm, or from about 2 to about 100 nm. In certain embodiments, each
type of the electroactive subparticles in the electroactive agglomerated
particles independently has an average particle size of about 10 nm,
about 20 nm, about 30 nm, about 40 nm, about 50 nm, about 60 nm, about 70
nm, about 80 nm, about 90 nm, about 100 nm, about 110 nm, about 120 nm,
about 130 nm, about 140 nm, or about 150 nm.

[0172] In certain embodiments, at least one type of the electroactive
subparticles used herein is coated to provide additional desired chemical
and/or physical properties, such as chemical inertness (by coating with
metal oxides, such as TiO2, MoO3, WO3, Al2O3, or
ZnO) or electrical conductivity (by coating with, e.g., ionic conductors
or carbon). In certain embodiments, at least one type of the
electroactive subparticles used herein is coated with a metal oxide by
mixing the electroactive subparticles with the metal oxide, e.g., in a
grinder. In certain embodiments, at least one type of the electroactive
subparticles used herein is coated with a metal oxide by mixing the
electroactive subparticles with a solution of polytitanic acid,
polytungstic acid, polymolybdic acid, polytitanic acid peroxide,
polytungstic acid peroxide, or polymolybdic acid peroxide, which forms
the corresponding metal oxide upon dehydration.

[0173] In certain embodiments, at least one type of the electroactive
subparticles used herein is coated with a carbonized carbon layer. In
certain embodiments, at least one type of the electroactive subparticles
used herein is first treated with a binder, including, but not limited
to, asphalt pitch, pitch coke, petroleum coke, a sugar, coal tar,
fluoranthene, pyrene, chrysene, phenanthrene, anthracene, naphthalin,
fluorine, biphenyl, acenephthene, or a mixture thereof; and subsequently
carbonized, in one embodiment, in an inert gas atmosphere, to form
carbonized carbon layer on the surface of the electroactive subparticles.

[0174] In certain embodiments, at least one type of the electroactive
subparticles used herein is coated with carbon by thermal vapor
deposition (CVD), as described in U.S. Pat. App. Pub. No. 2003/025711,
the disclosure of which is incorporated herein by reference in its
entirety.

Polymeric Overcoating

[0175] In one embodiment, the polymeric overcoating is an organic polymer.
Suitable polymeric overcoatings include, but are not limited to,
polyamideimides, polyimides, polytetrafluoroethylene (PTFE),
carboxymethyl cellulose (CMC), polyvinylidene fluoride (PVDF), polyvinyl
alcohol (PVA), styrene butadiene rubber (SBR), and mixtures thereof. In
certain embodiments, the polymeric overcoating is a polyamideimide. In
certain embodiments, the polymeric overcoating is a polyimide. In certain
embodiments, the polymeric overcoating is a carboxymethyl cellulose.

[0176] In certain embodiments, the polymeric overcoating material is a
crosslinkable polymer. Suitable crosslinkable polymers include, but are
not limited to, polybenzophenones, polyacrylates, polyvinyls,
polystyrenes, polysulfones, 2,3-dihydrofuran-containing polymers,
carboxymethyl celluloses (CMC), polyamideimides, polyimides,
styrene-containing copolymers, and mixtures thereof. In certain
embodiments, the crosslinkable polymer is a polyamideimide. In certain
embodiments, the crosslinkable polymer is a polyimide. In certain
embodiments, the crosslinkable polymer is a carboxymethyl cellulose.

[0177] In certain embodiments, the polymeric overcoating material is a
crosslinked polymer. Suitable crosslinked polymers include, but are not
limited to, polybenzophenones, polyacrylates, polyvinyls, polystyrenes,
polysulfones, 2,3-dihydrofuran-containing polymers, carboxymethyl
celluloses (CMC), polyamideimides, polyimides, styrene-containing
copolymers, and mixtures thereof. In certain embodiments, the crosslinked
polymer is a polyamideimide. In certain embodiments, the crosslinked
polymer is a polyimide. In certain embodiments, the crosslinked polymer
is a carboxymethyl cellulose.

[0182] In certain embodiments, the polymeric overcoating is formed from
its precursors via polymerization on the surface of the core of the
coated electroactive particle provided herein. In certain embodiments,
the precursors of a polymer are monomers of the polymer. In certain
embodiments, the precursors of a polymer are crosslinkable polymers. In
certain embodiments, the polyamideimide as a polymeric overcoating is
formed from a polyamideimide via crosslinking on the surface of the core
of the coated electroactive particle provided herein. In certain
embodiments, the polyimide as a polymeric overcoating is formed from a
polyimide via crosslinking on the surface of the core of the coated
electroactive particle provided herein.

[0183] In one embodiment, the polymeric overcoating is a polyamideimide,
polyimide, or a mixture thereof. In certain embodiments, the
polyamideimide is aromatic, aliphatic, cycloaliphatic, or a mixture
thereof. In certain embodiments, the polyamideimide is an aromatic
polyamideimide. In certain embodiments, the polyamideimide is an
aliphatic polyamideimide. In certain embodiments, the polyamideimide is a
cycloaliphatic polyamideimide. In certain embodiments, the polyimide is
aromatic, aliphatic, cycloaliphatic, or a mixture thereof. In certain
embodiments, the polyimide is an aromatic polyimide. In certain
embodiments, the polyimide is an aliphatic polyimide. In certain
embodiments, the polyimide is a cycloaliphatic polyimide.

[0184] In certain embodiments, the polymeric overcoating is TORLON®
AI-30, TORLON® AI-50, TORLON® 4000, or TORLON® 4203L (Solvay
Advanced Polymers, L.L.C., Ao0yaretta, GA); or formed from U-VARNISH®
(UBE American Inc., New York, N.Y.). In certain embodiments, the
polymeric overcoating is TORLON® AI-30. In certain embodiments, the
polymeric overcoating is TORLON® AI-50. In certain embodiments, the
polymeric overcoating is TORLON® 4000. In certain embodiments, the
polymeric overcoating is TORLON® 4203L. In certain embodiments, the
polymeric overcoating is a polyimide formed from U-VARNISH® (UBE
American Inc., New York, N.Y.).

[0186] In certain embodiments, the polyamideimide as a polymeric
overcoating is formed from a polyanhydride and a polyamine via
polymerization on the surface of the core of the coated electroactive
particle provided herein.

[0187] In certain embodiments, the polyimide as a polymeric overcoating is
formed from a polyanhydride and a polyamine via polymerization on the
surface of the core of the coated electroactive particle provided herein.

[0188] In certain embodiments, the aromatic, aliphatic, or cycloaliphatic
polyamideimide overcoating is formed via a condensation reaction of an
aromatic, aliphatic, or cycloaliphatic polyanhydride, in one embodiment,
a dianhydride, with an aromatic, aliphatic, or cycloaliphatic polyamine,
in one embodiment, a diamine or triamine.

[0189] In certain embodiments, the aromatic, aliphatic, or cycloaliphatic
polyimide overcoating is formed via a condensation reaction of an
aromatic, aliphatic, or cycloaliphatic polyanhydride, in one embodiment,
a dianhydride, with an aromatic, aliphatic, or cycloaliphatic polyamine,
in one embodiment, a diamine or triamine, to form a polyamic acid;
followed by chemical or thermal cyclization to form the polyimide.

[0190] Suitable polyanhydrides, polyamines, polyamideimide, and polyimides
include those described in Eur. Pat. App. Pub. Nos. EP 0450549 and EP
1246280; U.S. Pat. No. 5,504,128; and U.S. Pat. Appl. Pub. Nos.
2006/0099506 and 2007/0269718, the disclosure of each of which is
incorporated herein by reference in its entirety.

[0194] In certain embodiments, a conductive polymer is also added to the
polymeric overcoating to increase the conductivity of the coated
electroactive particle. Suitable conductive polymers include, but are not
limited to, polythiophene, poly(3-hexylthiophene),
poly(2-acetylthiophene), polybenzothiopnene, poly(2,5-dimethylthiophene),
poly(2-ethylthiophene), poly(3-carboxylic ethyl thiophene),
polythiopheneacetonitrile, poly(3,4-ethylenedioxythiophene),
polyisothianaphthene, polypyrrole, polyaniline, and polyparaphenylene. In
certain embodiments, the conductive polymer is added to the overcoating
polymer or precursors in an amount ranging from about 1 to about 40%,
from about 2 to about 20%, from about 3 to about 15%, or from about 5 to
about 10% of the total weight of the polymeric overcoating polymer and
the conductive polymer. In certain embodiments, the conductive polymer is
added to the overcoating polymer or precursors first before contacting
with the electroactive agglomerated particles or the subparticles.

Methods of Preparation

[0195] a. Electroactive Agglomerated Particles

[0196] In one embodiment, provided herein is a method for preparing the
electroactive agglomerated particles provided herein, which comprises
mixing subparticles of a first electroactive material and subparticles of
a second electroactive material to form the electroactive agglomerated
particles. The mixing step can be performed using any conventional method
known to one of ordinary skill in the art, including, but not limited to,
ball mixing, and cospraying, such as thermal spraying and ultrasonic
spraying. The production method will depend on the nature of the
subparticles employed.

[0197] In another embodiment, the method further comprises heating the
electroactive agglomerated particles at an elevated temperature. In
certain embodiments, the elevated temperature is ranging from about 200
to about 1000° C., from about 250 to about 750° C., from
about 250 to about 700° C., from about 250 to about 600°
C., from about 250 to about 500° C., or from about 250 to about
400° C.

[0201] In yet another embodiment, microsized agglomerates of LiFePO4
subparticles and metal oxide subparticles, and coal tar, are prepared by
air-injecting LiFePO4 subparticles, metal oxide subparticles, and
coal tar, independently and simultaneously, from three tubes into a
flowing bed.

[0202] In yet another embodiment, the electroactive agglomerated particles
provided herein, which comprise LiFePO4 subparticles, metal oxide
subparticles, and coal tar, are prepared by air-injecting LiFePO4
subparticles, and coal tar, independently and simultaneously, from three
tubes into a flowing bed.

[0204] In still another embodiment, the electroactive agglomerated
particles provided herein, which comprise LiFePO4 subparticles,
metal oxide subparticles, metal subparticles (such as Al, Ti, or Cr), and
coal tar, are prepared by air-injecting LiFePO4 subparticles, metal
oxide subparticles, metal subparticles, and coal tar, independently and
simultaneously, from four tubes into a flowing bed.

[0205] The certain embodiments, the methods provided herein further
comprise the step of grinding the coated electroactive particles into
predetermined particle sizes.

b. Coated Electroactive Particles

[0206] In one embodiment, provided herein is a method for preparing the
coated electroactive particles provided herein, which comprises the steps
of: i) covering the surfaces of the electroactive agglomerated particles
provided herein with a layer of a polymer in a solvent; and ii) curing
the electroactive agglomerated particles at an elevated temperature to
form the coated electroactive particles. In certain embodiments, the
polymer is a crosslinkable polymer. In certain embodiments, the polymer
is a polyamideimide. In certain embodiments, the polymer is a polyimide.

[0207] In another embodiment, provided herein is a method for preparing
the coated electroactive particles provided herein, which comprises the
steps of: i) covering the surfaces of electroactive agglomerated
particles provided herein with a layer of a mixture of precursors of a
polymer in a solvent; and ii) curing the electroactive agglomerated
particles at an elevated temperature form the coated electroactive
particles. In certain embodiments, the polymer is a crosslinked polymer.
In certain embodiments, the polymer is a crosslinkable polymer. In
certain embodiments, the precursors are crosslinkable polymers. In
certain embodiments, the precursors are monomers. In certain embodiments,
the polymer is a polyamideimide. In certain embodiments, the polymer is a
polyimide. In certain embodiments, the precursors are crosslinkable
polyamideimides. In certain embodiments, the precursors are crosslinkable
polyimides. In certain embodiments, the precursors are a polyanhydride
and polyamine.

[0208] In yet another embodiment, provided herein is a method for
preparing the coated electroactive particles provided herein, which
comprises the steps of: i) mixing electroactive agglomerated particles
provided herein with a polymer in a solvent to form a slurry; ii)
air-injecting the slurry to form particles; and iii) curing the particles
from step ii) at an elevated temperature to form the coated electroactive
particles. In certain embodiments, the polymer is a crosslinkable
polymer. In certain embodiments, the polymer is a polyamideimide. In
certain embodiments, the polymer is a polyimide. In certain embodiments,
the solid content in the slurry is ranging from about 10 to about 90% by
weight, from about 20 to about 90% by weight, from about 30 to about 70%
by weight, or from about 40 to about 60% by weight. In certain
embodiments, the solid content in the slurry is about 10% by weight,
about 20% by weight, about 30% by weight, about 35% by weight, about 40%
by weight, about 45% by weight, about 50% by weight, about 55% by weight,
about 60% by weight, about 65% by weight, about 70% by weight, about 80%
by weight, or about 90% by weight.

[0209] In yet another embodiment, provided herein is a method for
preparing the coated electroactive particles provided herein, which
comprises the steps of: i) mixing electroactive agglomerated particles
provided herein with a mixture of precursors of a polymer in a solvent to
form a slurry; ii) air-injecting the slurry to form particles; and iii)
curing the particles from step ii) at an elevated temperature to form the
coated electroactive particles. In certain embodiments, the polymer is a
crosslinked polymer. In certain embodiments, the polymer is a
crosslinkable polymer. In certain embodiments, the precursors are
crosslinkable polymers. In certain embodiments, the precursors are
monomers. In certain embodiments, the polymer is a polyamideimide. In
certain embodiments, the polymer is a polyimide. In certain embodiments,
the precursors are crosslinkable polyamideimides. In certain embodiments,
the precursors are crosslinkable polyimides. In certain embodiments, the
precursors are a polyanhydride and polyamine.

[0210] In yet another embodiment, provided herein is a method for
preparing the coated electroactive particles provided herein, which
comprises the steps of: i) mixing subparticles of a first electroactive
material and subparticles of a second electroactive material with a
polymer in a solvent to form a slurry; ii) air-injecting the slurry to
form agglomerated particles; and iii) curing the agglomerated particles
from step ii) at an elevated temperature to form the coated electroactive
particles. In certain embodiments, the polymer is a crosslinkable
polymer. In certain embodiments, the polymer is a polyamideimide. In
certain embodiments, the polymer is a polyimide.

[0211] In still another embodiment, provided herein is a method for
preparing the coated electroactive particles provided herein, which
comprises the steps of: i) mixing subparticles of a first electroactive
material and subparticles of a second electroactive material with a
mixture of precursors of a polymer in a solvent to form a slurry; ii)
air-injecting the slurry to form particles; and iii) curing the particles
from step ii) at an elevated temperature to form the coated electroactive
particles. In certain embodiments, the polymer is a crosslinked polymer.
In certain embodiments, the polymer is a crosslinkable polymer. In
certain embodiments, the precursors are crosslinkable polymers. In
certain embodiments, the precursors are monomers. In certain embodiments,
the polymer is a polyamideimide. In certain embodiments, the polymer is a
polyimide. In certain embodiments, the precursors are crosslinkable
polyamideimides. In certain embodiments, the precursors are crosslinkable
polyimides. In certain embodiments, the precursors are a polyanhydride
and polyamine.

[0212] The certain embodiments, the methods provided herein further
comprise the step of grinding the coated electroactive particles into
predetermined particle sizes.

[0213] The mixing step can be performed using any conventional method
known to one of ordinary skill in the art, including, but not limited to,
ball mixing, cospraying, such as thermal spraying and ultrasonic
spraying. The production method will depend on the nature of the
subparticles or the agglomerated particles employed.

[0214] In certain embodiments, the elevated temperature is ranging from
about 100 to about 1,000° C., from about 150 to about 750°
C., from about 200 to about 700° C., from about 300 to about
600° C., or from about 300 to about 500° C. In certain
embodiments, the elevated temperature is about 200° C., about
250° C., about 300° C., about 350° C., about
400° C., about 450° C., about 500° C., about
550° C., or about 600° C.

[0215] In certain embodiments, the solvent is N-methylpyrrolidinone (NMP).

Cathodes

[0216] In one embodiment, provided herein is a cathode that comprises the
electroactive agglomerated particles or coated electroactive particles
provided herein, a current collector, and optionally a binder.

[0217] Examples of suitable materials for the current collector include,
but are not limited to, aluminum, nickel, silver, and combinations
thereof. Some suitable binders include those as described herein. In
certain embodiments, the binder is selected from the group consisting of
polyvinylidene fluoride (PVDF), carboxymethyl cellulose (CMC), styrene
butadiene rubber (SBR), polyamideimides, polyimides, ethylene propylene
diene monomer (EPDM), polyethylene oxides (PEO or PEG),
polyethersulfones, polyphenylsulfones, and mixtures thereof.

[0218] In certain embodiments, the cathode is prepared by pressing the
electroactive agglomerated particles or coated electroactive particles
provided herein onto a current collector (e.g., a foil, strip, or sheet)
to form a cathode. In certain embodiments, the cathode is prepared by
dispersing the electroactive agglomerated particles or coated
electroactive particles provided herein into a solvent, in one
embodiment, N-methylpyrrolidinone (NMP), to form a slurry; and coating
the slurry onto a current collect.

Lithium Secondary Battery

[0219] In certain embodiments, provided herein is a lithium secondary
battery, which comprises a cathode comprising the agglomerated particles
or coated electroactive particles provided herein, and optionally a
binder; an anode; and an electrolyte that separates the anode and
cathode.

[0220] The anode can be any anode for a lithium secondary battery known to
one of ordinary skill in the art. In one embodiment, the anode comprises
a current collector, an electroactive material, and optionally a binder,
wherein the electroactive material is coated onto the surface of the
current collector.

[0221] In certain embodiments, the current collector of the anode is
copper. In certain embodiments, the current collector is copper. In
certain embodiments, the current collector is copper foil. In certain
embodiments, the current collector is rolled copper foil. In certain
embodiments, the current collector is electrodeposited copper foil. In
certain embodiments, the copper has a horizontal tensile strength ranging
from about 100 to about 500 N/mm2, from about 200 to about 450
N/mm2, from about 250 to about 450 N/mm2, or from about 300 to
about 400 N/mm2. In certain embodiments, the copper has a horizontal
tensile strength of about 200, about 220, about 240, about 260, about
270, about 280, about 290, about 300, about 310, about 320, about 330,
about 340, about 360, about 380, about 400, about 420, about 440, about
460, about 480, or about 500 N/mm2. In certain embodiments, the
copper has a vertical tensile strength ranging from about 100 to about
500 N/mm2, from about 200 to about 450 N/mm2, from about 250 to
about 450 N/mm2, or from about 300 to about 400 N/mm2. In
certain embodiments, the copper has a vertical horizontal strength of
about 200, about 220, about 240, about 260, about 270, about 280, about
290, about 300, about 310, about 320, about 330, about 340, about 360,
about 380, about 400, about 420, about 440, about 460, about 480, or
about 500 N/mm2.

[0222] In certain embodiments, the electroactive material of the anode is
a carbonaceous material. In certain embodiments, the electroactive
material is mesocarbon microbead. In certain embodiments, the
carbonaceous material is graphite, coke, petroleum coke, carbon, a
partially or fully graphitized carbon, carbon-black, hard carbon, or a
mixture thereof. In certain embodiments, the electroactive material of
the anode is coated electroactive particles as described in U.S.
Provisional Pat. Appl. Ser. No. 61/232,431, filed Aug. 9, 2009, the
disclosure of which is incorporated herein by reference in its entirety.

[0223] Some suitable binders for the anode include those as described
herein. In certain embodiments, the binder is selected from the group
consisting of polyvinylidene fluoride (PVDF), carboxymethyl cellulose
(CMC), styrene butadiene rubber (SBR), polyamideimides, polyimides,
ethylene propylene diene monomer (EPDM), polyethylene oxides (PEO or
PEG), polyethersulfones, polyphenylsulfones, and mixtures thereof.

[0224] Any electrolytes known to one of ordinary skill in the art can be
used in the battery provided herein. In certain embodiments, the
electrolyte comprises one or more lithium salts and a charge carrying
medium in the form of a solid, liquid, or gel. Suitable lithium salts
include, but are not limited to LiPF6, LiBF4, LiClO4,
lithium bis(oxalato)borate, LiN(CF3SO2)2,
LiN(C2F5SO2)2, LiAsF6,
LiC(CF3SO2)3, and combinations thereof.

[0226] The disclosure will be further understood by the following
non-limiting examples.

EXAMPLES

Example 1

Electrode and Cell Fabrication

[0227] Negative and positive electrodes were coated onto an Al foil and Cu
foil, respectively, using a small doctor blade coater, and then
calendared to designed thickness. The electrodes were then slited to
designed width and dried in a vacuum oven at an elevated temperature.
Once the electrodes were dried, all subsequent cell fabrication steps
were carried out inside a drying room at a Dew point of about -35°
C. The electrodes were tabbed first and then wound into jellyrolls. The
jellyrolls were then inserted into an 18650 can and an EC based
electrolyte was put into the cell under vacuum. The cells were crimped
for sealing after electrolyte filling. The cell was then be aged and
formed.

Example 2

Cell Testing

[0228] The cell was tested one week after formation. The cell capacities
and voltage profiles at ˜1 C and ˜5 C (or ˜10 C for the
Mn mixed particle) were measured by the following procedure: i) the cell
was charged to 3.9V at 0.6A for 2.5 hours; ii) the cell then rested for
several minutes; iii) the cell was discharged to 2.2 V at 1 C rate; iv)
the cell rested for another several minutes; v) the cell was then charged
to 3.9V at 0.6 A; vi) the cell rested for several minutes; and vii) the
cell was discharged to 2.2 V at ˜5 C or ˜10 C depending on
the mixed particles.

Example 3

Preparation of Electroactive Agglomerated Particles

[0229] Electroactive agglomerated particles comprising LiFePO4
nanoparticles, metal oxide nanoparticles, coal tar, and carbon black were
prepared by mixing LiFePO4 and metal oxide nanoparticles together,
contacting the subparticle mixture with a coal tar fume and carbon black,
and ball mixing the nanoparticle mixture. The metal oxide particles used
herein are LiMn2O4, Li(NiCoMn)1/3O2, or
LiAl0.05Ni0.8Co0.15O2 nanoparticles. The
electroactive agglomerated particles can be crushed into predetermined
particle sizes (e.g., in the range of about 1 to about 50 μm).

Example 4

Preparation of Electroactive Agglomerated Particles

[0230] Fe2O3 is mixed with Li2CO3 and
(NH4)2HPO4 in the presence of carbon. To the mixture are
then added nanoparticles of a second electroactive material. The mixture
is then thoroughly mixed again. The resulting mixture is heated under
N2 at an elevated temperature from about 700 to about 850° C.
to yield electroactive agglomerated particles comprising LiFePO4
nanoparticles and the nanoparticles of a second electroactive material.
The electroactive agglomerated particles can be crushed into
predetermined particle sizes (e.g., in the range of about 1 to about 50
μm).

Example 5

Preparation of Electroactive Agglomerated Particles

[0231] Fe2O3 particles are mixed with LiH2PO4 and
Mg(OH)2 particles in the presence of carbon. To the mixture are
added nanoparticles of a second electroactive material. The mixture is
then thoroughly mixed. The resulting mixture is heated under N2 at
an elevated temperature from about 700 to about 850° C. to yield
electroactive agglomerated particles comprising
LiFe1-xMgxPO4 nanoparticles and the nanoparticles of a
second electroactive material, where x is as defined herein. The
electroactive agglomerated particles can be crushed into predetermined
particle sizes (e.g., in the range of about 1 to about 50 μm).

Example 6

Preparation of Electroactive Agglomerated Particles

[0232] LiFePO4 is prepared via a sol-gel synthesis from
Fe(NO3)3.9H2O, lithium acetate dehydrate, and phosphoric
acid (85%). The iron nitrate and lithium acetate are combined with
phosphoric acid (85%) in a stoichiometric ratio of 1:1:1. Distilled water
is then added until all the constituents are completely dissolved.
Nanoparticles of a second electroactive material, such as a metal oxide,
are added. The pH of the mixture is adjusted to 8.5 to 9.5 using
NH4OH to form a sol. The sol is then heated on a hot plate with
stiffing to form a gel. The sample is then fired to 500° C. The
mixture is then ground using a planetary ball mill in a solvent, such as
ethanol and acetone. The grinding solvent is then evaporated under
nitrogen and the resulting powder is thoroughly mixed and fired to about
600° C. to yield embedded electroactive agglomerated particles
which comprises LiFePO4 nanoparticles and the nanoparticles of a
second electroactive material. The electroactive agglomerated particles
can be crushed into predetermined particle sizes (e.g., in the range of
about 1 to about 50 μm).

Example 7

Preparation of Electroactive Agglomerated Particles

[0233] LiFePO4, LiAl0.05Ni0.8Co0.15O2, and carbon
nanoparticles were ball mixed with coke. The mixture was hot spray dried
to form agglomerated particles, which were further heat treated at about
300° C. The agglomerated particles were then crushed to form
electroactive agglomerated particles having a particle size in the range
of 1 to 50 μm.

[0234] Two different types of electroactive agglomerated particles were
prepared. Agglomerated Particle I comprises about 78% by weight of
LiFePO4, about 20% by weight of
LiAl0.05Ni0.8Co0.15O2, and about 1.5% carbon.
Agglomerated Particle II comprises about 68% by weight of LiFePO4,
about 30% by weight of LiAl0.05Ni0.8Co0.15O2, and
about 1.2% carbon.

[0235] Their electrochemical properties were compared with those of
Physical Mixture II, which were a simple physical mixture comprising
about 68% by weight of LiFePO4, about 30% by weight of
LiAl0.05Ni0.8Co0.15O2, and about 1.2% carbon. The
results are summarized in Table 1.

[0236] The cycle life of the cells was determined by charging the cells to
4V at 0.7 C, resting for 10 min, and then discharging to 2.2 V at 0.5 C.
The capacity loss was calculated by the equation: (initial
capacity-capacity at the last cycle)/initial cell capacity.

Example 8

Preparation of Electroactive Agglomerated Particles

[0237] A uniform suspension of LiFePO4,
LiAl0.05Ni0.8Co0.15O2, carbon nanoparticles, and coke
in a solvent (e.g., NMP) is hot spray dried to form agglomerated
particles. The agglomerated particles are further heat treated at an
elevated temperature (e.g., about 300° C.) to form electroactive
agglomerated particles, which are then crushed into predetermined
particle sizes (e.g., in the range of about 1 to about 50 μm).

Example 9

Preparation of Coated Electroactive Particles

[0238] The agglomerated particles from one of Examples 3 to 8 are sprayed
with a solution of a polyamideimide (e.g., TORLON® AI-30, TORLON®
AI-50, TORLON® 4000, or TORLON® 4203L) in a solvent (e.g.,
N-methylpyrrolidinone). The wet agglomerated particles are further cured
at an elevated temperature (e.g., about 300° C.) to form coated
electroactive particles. The coated electroactive particles are then
crushed into predetermined particle sizes (e.g., in the range of about 1
to about 50 μm).

Example 10

Preparation of Coated Electroactive Particles

[0239] The agglomerated particles from one of Examples 3 to 8 are sprayed
with a solution of precursors of a polyimide (e.g., U-VARNISH®) in a
solvent (e.g., N-methylpyrrolidinone). The wet agglomerated particles are
further cured at an elevated temperature (e.g., about 300° C.) to
form coated electroactive particles. The coated electroactive particles
are then crushed into predetermined particle sizes (e.g., in the range of
about 1 to about 50 μm).

Example 11

Preparation of Coated Electroactive Particles

[0240] The agglomerated particles from one of Examples 3 to 8 are added to
a solution of a polyamideimide (e.g., TORLON® AI-30, TORLON®
AI-50, TORLON® 4000, or TORLON® 4203L) in a solvent (e.g.,
N-methylpyrrolidinone) to form a uniform suspension, which is hot spray
dried to form coated electroactive particles. The coated electroactive
particles are further cured at an elevated temperature (e.g., about
300° C.), and then crushed into predetermined particle sizes
(e.g., in the range of about 1 to about 50 μm).

Example 12

Preparation of Coated Electroactive Particles

[0241] The agglomerated particles from one of Examples 3 to 8 are added to
a solution of precursors of a polyimide (e.g., U-VARNISH®) in a
solvent (e.g., N-methylpyrrolidinone) to form a uniform suspension, which
is hot spray dried to form coated electroactive particles. The coated
electroactive particles are further cured at an elevated temperature
(e.g., about 300° C.), and then crushed into predetermined
particle sizes (e.g., in the range of about 1 to about 50 μm).

Example 13

Preparation of Coated Electroactive Particles

[0242] A uniform suspension of LiFePO4 nanoparticles, doped
LiNiO2 (e.g., LiAl0.05Ni0.8Co0.15O2)
nanoparticles, carbon nanoparticles, and coke in a solvent (e.g.,
N-methylpyrrolidinone) that contains a polyamideimide (e.g., TORLON®
AI-30, TORLON® AI-50, TORLON® 4000, or TORLON® 4203L) is hot
spray dried to form coated electroactive particles. The coated
electroactive particles are further cured at an elevated temperature
(e.g., about 300° C.), and then crushed into predetermined
particle sizes (e.g., in the range of about 1 to about 50 μm).

Example 14

Preparation of Coated Electroactive Particles

[0243] A uniform suspension of LiFePO4 nanoparticles, doped
LiNiO2 (e.g., LiAl0.05Ni0.8Co0.15O2)
nanoparticles, carbon nanoparticles, and coke in a solvent (e.g.,
N-methylpyrrolidinone) that contains precursors of a polyimide (e.g.,
U-VARNISH®) is hot spray dried to form coated electroactive
particles. The coated electroactive particles are further cured at an
elevated temperature (e.g., about 300° C.), and then crushed into
predetermined particle sizes (e.g., in the range of about 1 to about 50
μm).

Example 15

Preparation of Coated Electroactive Particles

[0244] Doped LiNiO2 (e.g. LiAl0.03Ni0.8Co0.17O2)
having an average particle size of 10 μm was cryomilled to form
nanoparticles having an average particle size of 100 nm. LiFePO4
having an average particle size of 0.5 to 2 μm was also cryomilled
into nanoparticles having an average particle size of 100 nm. The doped
LiNiO2 (30 g) and LiFePO4 (70 g) nanoparticles were then mixed
with a polyamideimide (1 g) in a solvent to form a slurry, which was
spray dried to form coated electroactive particles under the following
conditions: air pressure, 120 to 125 psi; out-temperature, 60° C.;
in-temperature, 150° C.; flow rate, 5.0 mL/min; and atomizing air,
0.2 MPa. The coated electroactive particles were further cured at an
elevated temperature (e.g., about 300° C.).

[0245] The coated electroactive particles were characterized with scanning
electron microscope/energy dispersive using X-ray analysis (SEM/EDX). The
coated electroactive particles shown in FIGS. 7A to 7D are spherical in
shape. The coated electroactive particles shown in FIGS. 8A to 8D are
spherical and/or spheroidal in shape. As shown in FIGS. 9A and 9B, the
EDX spectra of two individual beads from the same batch of preparation
are substantially the same, indicating that the coated electroactive
particles are homogenous. The coated electroactive particles in FIGS. 8
and 9 are from the same batch.

Example 16

Preparation of Coated Electroactive Particles

[0246] Doped LiNiO2 (e.g., LiAl0.03Ni0.8Co0.17O2)
and LiFePO4 nanoparticles were prepared as described in Example 15.
The doped LiNiO2 (30 g) and LiFePO4 (70 g) nanoparticles were
then mixed with CMC (1 g) in a solvent to form a slurry, which was spray
dried to form coated electroactive particles under the following
conditions: air pressure, 120 to 125 psi; out-temperature, 60° C.;
in-temperature, 150° C.; flow rate, 5.0 mL/min; and atomizing air,
0.2 MPa. The coated electroactive particles were further cured at an
elevated temperature (e.g., about 300° C.).

[0247] The coated electroactive particles were characterized with scanning
electron microscope/energy dispersive using X-ray analysis (SEM/EDX) and
the results are shown in FIGS. 10A to 10D.

[0248] The examples set forth above are provided to give those of ordinary
skill in the art with a complete disclosure and description of how to
make and use the claimed embodiments, and are not intended to limit the
scope of what is disclosed herein. Modifications that are obvious to
persons of skill in the art are intended to be within the scope of the
following claims. All publications, patents, and patent applications
cited in this specification are incorporated herein by reference as if
each such publication, patent or patent application were specifically and
individually indicated to be incorporated herein by reference.

Patent applications by Jiang Fan, San Diego, CA US

Patent applications in class HAVING UTILITY AS A REACTIVE MATERIAL IN AN ELECTROCHEMICAL CELL; E.G., BATTERY, ETC.

Patent applications in all subclasses HAVING UTILITY AS A REACTIVE MATERIAL IN AN ELECTROCHEMICAL CELL; E.G., BATTERY, ETC.